Article with reinforced nonstick food preparation surface

ABSTRACT

Cookware surfaces of metal, such as aluminum, may include a nonstick coating and embedded hard metal mesh. The mesh protects the nonstick coating between interior regions within the mesh from being cut or abraded by knives and other tools.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims the benefit of the filing date under 35U.S.C. §119(e) to U.S. Provisional Patent Application No. 62/299,669,filed on Feb. 25, 2016, the contents of which are hereby incorporated byreference in their entirety.

TECHNICAL FIELD

The present invention relates to cookware and surfaces thereof, such asfood preparation surfaces and induction heating features of pots, pans,platens, griddles and grills.

BACKGROUND

Some foods tend to stick to cookware surfaces. This tendency isparticularly common with heated cookware surfaces when preparing suchfoods. To combat this tendency, cookware articles may be outfitted withwhat is often referred to as “nonstick” or “easy release” cookingsurfaces. These surfaces typically include coated metal surfacesincluding fluorocarbons, such as PTFE; vitreous enamel; silicones; andceramics.

SUMMARY

In one aspect, a cookware article includes a base material layer, a meshlayer, and a nonstick coating layer. The base material layer may have atleast a first base surface along a first side. At least a first meshlayer may be disposed on the first base surface. The first mesh layermay include a plurality of first network segments embedded in the firstbase surface and that extend outward therefrom to a planar outer firstmesh surface. The first network segments may define a plurality of firstinterior regions between adjacent first network segments. The nonstickcoating layer may be disposed on the first base surface, within thefirst interior regions between the adjacent first network segments, andextend outward therefrom to an outer nonstick coating surface adjacentto the outer first mesh surface. The outer first mesh surface may bedisposed outward of the first base surface farther than the adjacentouter nonstick coating surface such that the nonstick coating surface isdisposed below the outer first mesh surface.

The first base surface and layers thereon may employ a variety ofconfigurations. For example, in various embodiments, each of the firstand second portions of the first base surface are planar. In furtherembodiments, the outer nonstick coating surface may include a pluralityof discrete surfaces interspersed between the first network segments.The first network segments may be interconnected and laterally surroundthe plurality of first interior regions. In one embodiment, the basematerial layer comprises aluminum and the first mesh layer comprisesstainless steel first network segments. Adjacent first network segmentsmay define one of parallelogram, hexagonal, or rhomboidal first interiorregions. For example, adjacent first network segments may definehexagonal interior regions.

In various embodiments, the base material layer may include a secondbase surface along a second side, opposite the first side. The cookwarearticle may further include a second mesh layer disposed on the secondbase surface. The second mesh layer may include a plurality of secondnetwork segments embedded in the second surface and extending outwardtherefrom to a planar outer second mesh surface and defining a pluralityof second interior regions between adjacent second network segments.

In one embodiment, the second base surface within the second interiorregions defined by the adjacent second network segments has an outersecond base surface disposed outward beyond adjacent second basesurfaces in which the second network segments are embedded. In this oranother embodiment, the outer second mesh surface may be disposedoutward at least as far as adjacent outer second base surfaces. Each ofthe first and second base surfaces may be planar. In furtherembodiments, the outer nonstick coating surface may include a pluralityof discrete surfaces interspersed between the first network segments,and the outer second base surface may include a plurality of discretesurfaces interspersed between the second network segments. The firstnetwork segments may be interconnected and laterally surround theplurality of first interior regions, and the second network segments maybe interconnected and laterally surround the plurality of secondinterior regions.

The layers may include various materials. In one example, at least oneof the first network segments, the second network segments, or bothinclude stainless steel. In a further example, the first networksegments include stainless steel and the second network segments includemagnetic stainless steel alloy. In some embodiments, the base materiallayer may include aluminum. The base material layer may also includecopper or other suitable metal or alloy.

The network segments may include various shapes, sizes, and patterns.For example, in one embodiment, the adjacent first network segmentsdefine hexagonal first interior regions.

The features of the cookware article surface may be configured withvarious dimensions. For example, interior regions may have a surfacedimension between about 0.8 mm and about 2 mm. In this or anotherembodiment, network segments have a width of between about 0.3 mm andabout 0.5 mm. In any of the above or another embodiment, networksegments may have a thickness between about 0.5 mm to about 1 mm normalto the cookware article surface. In any of the above or a furtherembodiment, the base material layer is between 3 mm and 4 mm thick.

Various cookware articles employing the inventive surface features mayinclude a pot, pan, tray, platter, platen, grill, griddle surface,baking tray or pizza pan.

In another aspect, a method of making a surface of a cookware articlemay include providing a base material including a metal or metal alloyand coating at least one planar surface of the metal or alloy with anorganic nonstick material. The method may further include compressing amesh comprising a plurality of network segments including a metal ormetal alloy onto the coated surface to embed the network segments intothe base material. The network segments may define a plurality ofinterior regions between adjacent network segments. The network segmentsmay also extend outward of the base material beyond the nonstickmaterial.

In various embodiments, the method may further include compressing amesh comprising a plurality of network segments including a metal ormetal alloy onto another surface of the base material located on anopposite side thereof. The network segments may define a plurality ofinterior regions between adjacent network segments. The network segmentsmay extend outward of the base material at least as far as outersurfaces of the base material layer within the interior regions definedbetween the network segments.

The above and other objects, effects, features, and advantages of thepresent invention will become more apparent from the followingdescription of the embodiments thereof taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Novel features of the present invention are set forth with particularityin the appended claims. However, the various embodiments of the presentinvention described herein, both as to organization and manner ofoperation, may be best understood by reference to the followingdescription, taken in conjunction with the accompanying drawings inwhich:

FIG. 1A is a schematic cross-sectional elevation view of an upperportion of a cookware article surface according to various embodimentsdescribed herein, whereas FIG. 1B is a top plan view thereof.

FIG. 2A is a schematic cross-sectional elevation view of an upperportion of a cookware article surface according to various embodimentsdescribed herein, whereas FIG. 2B is a top plan view thereof.

FIG. 3 is a schematic cross-sectional elevation view of a portion of acookware article surface according to various embodiments describedherein.

FIG. 4A is a cross-sectional elevation of a cookware article surfaceaccording to various embodiments described herein, where FIG. 4B is thecookware article surface of FIG. 4A formed into a cooking pan.

DESCRIPTION

Nonstick or easy release cooking surfaces are typically deployed ascoatings. The durability of these coatings may be enhanced throughchemistry, particulate reinforcement, and layers. However, even whenenhanced, nonstick or easy release coatings may still be easilyscratched or cut by hard tools or other cookware, such as cookwareutensils including sharp tools like knives and circular pizza cutters,or with similar sharp instruments. Thus, this lack of durability alsolimits cross-use of cookware articles that may damage a coating ofeither article.

According to various embodiments, the present disclosure describesreinforced nonstick cookware article surfaces, generally denominatedarticle surface 100 in FIGS. 1A-4B, wherein like reference numeralsrefer to like components in the various views. The cookware articlesurface 100 may comprise one or more layers of materials. The cookwarearticle surface 100 may be embodied in any cookware article, such aspots, pans, platens, griddles, grills, roasting pans, utensils, and thelike. The surface 100 may be constructed to allow users to cut and slicefood on the article surface 100, without damaging the nonstick finish.In some embodiments, for example, the surface 100 comprises a cutresistant nonstick construction for cookware articles such as pots,pans, platens, griddles, grills, roasting pans, and the like. Whilereferred to herein as surface 100, it should be understood that thelayered material of the surface 100 may form an expanse of a wall,through the thickness of the wall, of a cookware article or may befurther layered onto another material to form an expanse of a wall of acookware article.

With reference to FIGS. 1A & 1B, the cookware article surface 100 mayinclude a base material layer 110. The base material layer 110 willtypically include a thermally conductive material such as a metal. Thebase material layer 110 may preferably be a malleable metal, such as asoft metal, e.g., aluminum, copper, or alloys thereof. In oneembodiment, for example, the base material 110 is aluminum.

The cookware article surface 100 may also include a mesh layer 120disposed over at least a portion of a surface 111 of the base materiallayer 110. The portion of the surface 111 onto with the mesh layer 120is disposed will typically be planar. Thus, the mesh layer 120 may bedisposed over a planar surface portion of the surface 111. The meshlayer 120 includes a plurality of network segments 121 arranged alongthe surface 111 of the base material layer 110 that extend outwardtherefrom to together define a generally planar outer mesh surface 122above the base material surface 111. Adjacent network segments 121 alongthe mesh layer 120 may define a plurality interior regions 123. Theinterior regions 123 may have various shapes and sizes as described inmore detail below. The interior regions 123 may be patterned to includeconsistent sizes, shapes, and alignments. The network segments 121 maybe interconnected to laterally surround interior regions 123 or may bepartially or entirely disconnected to partially laterally surroundinterior regions 123. The mesh layer 120 may embed within the surface111 of the base material layer 110. For example, as shown, inwardlypositioned portions of the network segments 121 that interface with thesurface 111 may embed in the base material layer 110.

The cookware article surface 100 may also include a nonstick coatinglayer 130 that coats a portion of the surface 111 of the base materiallayer 110 between the adjacent network segments 121 within the interiorregions 123. The nonstick coating layer 130 may extend outward of thebase material layer 110 to an outer nonstick coating surface 132adjacent to the planar outer mesh surface 122. Thus, the nonstickcoating layer 130 may be interspersed among the network segments 121 totogether with the mesh layer 120 provide an outer surface comprising aplurality of outer nonstick coating surface 132 regions disposed betweenouter mesh surface 122 regions. In various embodiments, the outernonstick coating surface 132 may include discrete or interconnectedregions. In the embodiment illustrated in FIG. 1B, the mesh layer 120includes a plurality of interconnected network segments 121 positionedover a planar portion of the surface 111 of the base material layer 110that are arranged to laterally surround interior regions 123 and, hence,discrete portions of the nonstick coating layer 130 disposed therein.

Interior regions 123 may preferably have a spacing dimension betweennetwork segments 121 or surface dimension such as diameter between about0.8 mm and about 2 mm. Smaller dimensions or larger dimensions may alsobe used. The width of the network segments 121 between the interiorregions 123 may preferably be between about 0.3 mm and about 0.5 mm,although smaller or larger width dimensions may also be used. Thethickness of the network segments 121 may also preferably be betweenabout 0.5 mm to about 1 mm normal to the cookware article surface 100;however, smaller or larger thicknesses may be used. In variousembodiments, the base material layer 110 may preferably be between 3 mmand 4 mm thick, although smaller or larger thicknesses may be used.

It has been discovered that the ranges of dimensions of the interiorregions 123 and the network segments 121 provide the benefits of easyfood release even from the surface 123 which is not coated withnon-stick material in regions 130. At the same time, the surface 123also protects the non-stick surface 132 from damage by cutting and foodpreparation utensils, such as knives, spatulas, tongs and the like.

It has also been discovered that the corrugation pattern enhances foodbrowning with a small quantity of cooking oil being used for thispurpose.

The base material layer 120 may be coated with the nonstick coatinglayer 130 according to any suitable method. For example, various USpatents teach compositions of matter and methods of applying organicbased and nonstick coatings to cookware vessels. These include U.S. Pat.No. 3,986,993 to Vassiliou (issued Oct. 19, 1976); U.S. Pat. No.4,118,537 to Vary, et al. (issued Oct. 3, 1978); U.S. Pat. No. 4,321,177to Wilkinson (issued Mar. 23, 1982); U.S. Pat. No. 5,691,067 to Patel(issued Oct. 25, 1997) and U.S. Pat. No. 6,133,359 to Bate, et al.(issued Oct. 17, 2000), all of which are incorporated herein byreference. The nonstick coating layer 130 may typically contain one ormore low surface energy polymers of resin, particularly fluorinatedresins or fluorinated silicone resins, and silicone resins, including,PTFE (polytetrafluoroethylene), FEP (fluorinated ethylene propylene),PFA (Perfluoroalkoxy) and combinations thereof, along with reinforcingfillers such as glass, aluminum oxide titanium oxide, silicon carbide,and the like, and may preferably be deposited as multilayer coatingswith varying compositions so the exposed outer surface, though softer,is more chemically inert and water and oil repellent. The nonstickcoating layer 130 may also include one or more binder resins such aspolyamide-imide (PAI), polyphenylene sulphide (PPS), polyether sulphone(PES), or a silicone and possibly also pigments.

In various embodiments, the mesh layer 120 may be embedded into the basematerial layer 110 by force. For example, surface 111 of the basematerial layer 110 may be coated with the nonstick coating layer 130 andthe mesh layer 120 may be forced against the exposed nonstick coatinglayer 130. As the mesh layer 120 is embedded by force into the basematerial layer 110 it penetrates the nonstick coating layer 130 which isthen exposed within the interior regions 123 between the networksegments 121 of the mesh layer 120. The embedding process may result inthe planar outer mesh surface 122 being disposed no lower than the outernonstick coating surface 132 positioned within the interior regions 123along the outer surface. In some embodiments, the outer mesh surface 122is approximately level with the outer nonstick coating surface 132. Inother embodiments, the outer mesh surface 122 extends beyond the outernonstick coating surface 132, such as between 0 mm and about 0.01 mm, orbetween about 0.01 mm and about 0.1 mm.

The mesh layer 120 preferably comprises a metal material, includingalloys thereof, harder than the organic nonstick coating material of thenonstick coating layer 130 and the base material of the base materiallayer 110. For example, a mesh layer 120 formed of stainless steelnetwork segments 121 may be readily embedded into an aluminum basematerial after a nonstick coating layer 130, as stainless steel networksegments 121 are harder than both the aluminum base material and thenonstick coating material. The planar outer mesh surface 122 extendingbeyond or level with the nonstick coating outer surface 132 provides anetwork of protective shields that prevent hard surfaces, such as sharpsteel tool surfaces, from digging into the nonstick coating 130 withinthe interior regions 123.

FIGS. 2A & 2B illustrate another embodiment of the cookware articlesurface 100 comprising a base material layer 110, mesh layer 120, and anonstick coating layer 130. The layers 110, 120, 130 may be arranged ina manner similar to that described with respect to FIGS. 1A & 1B. Asshown in FIG. 1A and FIG. 2A, network segments 121 of 10 the mesh layer120 may be arranged to define various shaped interior regions 123. Forexample, interior regions 123 may have hexagonal shapes, e.g., as shownin FIG. 1A, or rectangular, parallelogram, or rhombus shapes. Othershapes may include arcuate, geometric, nongeometric, regular, orirregular shapes. In one embodiment, networks segments 121 definerhomboid or diamond shaped interior regions 123, e.g., as shown in FIG.2A. As introduced above, the interior regions 123 may be patterned alongthe cookware article surface 100 to include consistent or inconsistentsizes, shapes, and alignments. In one embodiment, network segments 121define interior regions 123 of multiple shapes, sizes, or both.

The mesh layer 120 may be formed by casting, forming, assembly, materialremoval techniques such as excising material from sheets, or othersuitable fabrication techniques to form the network segments 121. In oneexample, the arrangement of the network segments 121 of the mesh layer120 illustrated in FIG. 2A may be formed by introducing rows of discreteslits in a metal sheet and then expanding the sheet such that each slitmay then be opened to form connected network segments 121 whereinadjacent segments 121 define interior regions 123.

In various embodiments, a cookware article comprises the cookwarearticle surface 100. The cookware article surface 100 may optionally beany portion of a pot, pan, tray, platter, platen, grill, or griddlesurface, for example. In one embodiment, the cookware article surface100 is a portion of a nonstick surface of a baking tray, or pizza panwherein the mesh layer 120 protects the outer nonstick surface 132 froma knife blade, such as a mezzaluna, or circular pizza cutting wheel.

With reference to FIG. 3, in some embodiments, the cookware articlesurface 100 includes a base material layer 110 having multiple surfaces111, 111′ upon which mesh layers 120, 120′ are disposed. In suchembodiments, the base material layer 110 may be coated along at leastone of the surfaces 111, 111′ with a nonstick coating layer 130.Surfaces 111, 111′ including the nonstick coating layer 130 willtypically be surfaces 111, 111′ that are intended to or in which it isforeseeable will contact food during use.

In the illustrated embodiment, the cookware article surface 100comprises a base material layer 110, first and second mesh layers 120,120′, and a nonstick coating layer 130 wherein the first mesh layer 120and the nonstick coating layer 130 are disposed on a first surface 111of the base material layer 110 and the second mesh layer 120′ isdisposed on a second surface 111′ of the base material layer 110,generally opposite the first surface 111. The first mesh layer 120includes a plurality of first network segments 121 embedded in the firstsurface 111 and extending to a first outer mesh surface 122. Thenonstick coating layer 130 is disposed within interior regions 123defined by the first network segments 121 and extends outward from thefirst surface 111 to a plurality of outer nonstick coating surfaces 132in an arrangement similar to that described with respect to FIGS. 1A-2B.

The second mesh layer 120′ includes a plurality of second networksegments 121′ embedded in the second surface 111′ and extending to agenerally planar second outer mesh surface 122′. The second networksegments 121′ are arranged to define interior regions 123′ betweenadjacent segments 121′ within which the second surface 111′ of the basematerial layer 110 is exposed to form an outer base material surface112. In various embodiments, the base material layer 110 may preferablybe between 3 mm and 4 mm thick, although smaller or larger thicknessesmay be used. While the base material layer 110 is illustrated as thesame across and through the thickness of the expanse of the cookwarearticle surface 100, in various embodiments a same base material layermay not form both the first and second surfaces 111, 111′. For example,the base material layer 110 may comprise multiple base materials layers110.

The second network segments 121′ of the second mesh layer 120′ areillustrated as being embedded deeper in the base material layer 110 thanthe first network segments 121 of the first mesh layer 120. In otherembodiments the first network segments 121 may be embedded the samedepth or deeper than the second network segments 121′. The second outermesh surface 122′ is disposed no lower than the outer base materialsurface 112. Thus, the second outer mesh surface 122′ may extend outwardbeyond the outer base material surface 112 along the second surface111′. The outer base material surface 112 may also be level with secondouter mesh surface 122. The thickness of the second network segments121′ may be similar to the thickness of the first network segments. Forexample, in some embodiments, the thickness of the second networksegments 121′ may be between about 0.5 mm to about 1 mm normal to thecookware article surface 100; however, smaller or larger thicknesses maybe used. For example, first or second network segments 121, 121′ havinglarger thicknesses may be used to increase strength and durability.

The second network segments 121′ may be interconnected to laterallysurround interior regions 123′ or may be partially or entirelydisconnected to partially laterally surround interior regions 123′.Similarly, the outer base material surface 112 may be interconnected orcomprise discrete regions. For example, the outer base material surface112 may include a discrete surface region within each interior region123′ between interconnected second network segments 121′.

The second network segments 121′ of the second mesh layer 120′ areillustrated as having a width similar to the first network segments 121of the first mesh layer 120. For example, the width of the secondnetwork segments 121′ between the interior regions 123′ may preferablybe between about 0.3 mm and about 0.5 mm. In other embodiments, thefirst network segments 121 may have larger or smaller widths than thesecond network segments 121′. For example, the second network segments121′ may include thicknesses larger than 0.5 mm to increase inductioncapacity, when applicable, or the structural strength and durabilitytherealong.

The second network segments 121′ may define interior regions 123′ havingany shape, such as parallelogram, rhomboidal, hexagonal, arcuate,geometric, nongeometric, regular, or irregular shapes. The secondnetwork segments 121′ may also defined interior regions having shapes,sizes, or in arrangements similar to or different than the shapes,sizes, or arrangements defined by the first network segments 121. Insome embodiments, the second network segments are illustrated asdefining interior regions 123′ having similar diameters as the interiorregions 123 defined by the first network segments 121. For example, theinterior regions 123 may have a spacing dimension between networksegments 121 or surface dimension such as diameter between about 0.8 mmand about 2 mm. However, in other embodiments, second network segments121′ define interior regions 123′ having smaller or larger diametersthan the interior regions 123 defined by the first network segments 121.

The outer base material surface 112 may correspond to the outer nonstickcoating surface 132 in size, shape, or location. However, in otherembodiments, outer base material surface 112 may not correspond to theouter nonstick coating surface 132 with respect to one or more of size,shapes, or location.

The second mesh layer 120′ and second network segments 121′ thereof maycomprise materials and be fabricated in a manner similar to thatdescribed with respect to the first mesh layer 120. In variousembodiments, the second network segments 121′ may comprise a materialharder than the base material along the second surface 111′, such as ahard metal or alloy. In some embodiments, the second network segments121′ comprise stainless steel. In some embodiments, the second meshlayer 120′ may be configured to provide induction heating features. Forexample, the second network segments 121′ may comprise a ferromagneticmaterial. In one embodiment, the second mesh layer 120′ comprisesmagnetic stainless steel for induction heating of the first outersurfaces 122/132.

FIGS. 4A & 4B illustrate a cookware article surface 100 and the cookwarearticle surface 100 employed in a cookware article 10 comprising a pan(FIG. 4B) according to various embodiments. The cookware article surface100 may be similar to the cookware article surface 100 described withrespect to FIG. 3. For example, the cookware article surface 100comprises a base material layer 110, first and second mesh layers 120,120′, and a nonstick coating layer 130 wherein the first mesh layer 120and the nonstick coating layer 130 are disposed on a first surface 111of the base material layer 110 and the second mesh layer 120′ isdisposed on a second surface 111′ of the base material layer, generallyopposite the first surface 111. The first mesh layer 120 includes aplurality of first network segments 121 embedded in the first surface111 and extending to a first outer mesh surface 122. The nonstickcoating layer 130 is disposed within interior regions 123 defined by thefirst network segments 121 and extends outward from the first surface111 to a plurality of outer nonstick coating surfaces 132 in anarrangement similar to that described with respect to FIGS. 1A-2B. Thesecond mesh layer 120′ includes a plurality of second network segments121′ embedded in the second surface 111′ and extending to a generallyplanar second outer mesh surface 122′. The second network segments 121′are arranged to define interior regions 123′ between adjacent segments121′ within which the second surface 111′ of the base material layer 120is exposed to form an outer base material surface 112.

The second network segments 121′ disposed along the underside of the panare preferably magnetic stainless steel for induction heating of theouter surfaces 122/132. The first and second network segments 121, 121′may define interior regions 123, 123′ of any shape. In one embodiment,the first network segments 121, the second network segments 121′, orboth define hexagonal, parallelogram, rectangular, or rhomboidal shapedinterior regions 123, 123′ with a spacing dimension between networksegments 121 or surface dimension such as diameter between about 0.8 mmand about 2 mm. The width of the network segments 121, 121′ between theinterior regions 123, 123′ may preferably be between about 0.3 mm andabout 0.5 mm. The thickness of the network segments 121, 121′ may alsopreferably be between about 0.5 mm to about 1 mm normal to the cookwarearticle surface 100. The base material layer may preferably be between 3mm and 4 mm thick. The base material layer 110 along the second surface111′ may comprise similar base materials as described above with respectto FIGS. 1A-3. For example, the base material layer 110 along the secondsurface 111′ may comprise aluminum.

The dish shape of the cookware article 10 may be formed before or afterembedding the first mesh layer 120, second mesh layer 120, or both. Forexample, the network segments 121, 121′ may be embedded when a pot orpan is formed. Side surfaces 104, 104′ surround the planar cookingarticle surface 100. In various embodiments, interior or exterior sidesurfaces 104, 104′ may also include a mesh layer 120, 120′, nonsticklayer 130, or both. For example, in the illustrated embodiment, theinterior side surface 104 includes a nonstick layer. The cookwarearticle 10 is preferably made by embedding network segments 121, 121′ ina respective surface 111, 111′ of the base material layer 110 after anorganic nonstick material is coated onto the at least one surface 111,111′. The network segments 121, 121′ will first penetrate through thenonstick coating layer 130, but thereafter from a protective barrierfrom cutting tool, such as knives, mezzalunas, cutting wheels, spatulasand the like.

It will be appreciated that the embodiments illustrated in FIGS. 1A-2Bmay have a similarly configured opposite surfaces. For example, theembodiments illustrated in FIGS. 1A-2B may also include an oppositesurface comprising base material with embedded mesh disposed betweeninterior regions of base material similar to that described with respectto FIGS. 3-4B. In another example, the embodiments illustrated in FIGS.1A-2B may include an opposite surface comprising a nonstick materiallayered over the base material layer and a mesh layer embedded in thebase material and arranged in a manner similar to the base materiallayer 110, mesh layer 120, and nonstick layer 130 along the othersurface. In any of the above or another embodiment, an outer meshsurface along the opposite surface may extend outward beyond an outerbase surface or outer nonstick surface. In another embodiment, an outerbase surface along the opposite surface may be level with or extendoutwardly beyond the mesh surface portion. In yet another embodiment,the second surface 111′ may have a protective layer or coating over thebase material.

While the invention has been described in connection with a preferredembodiment, it is not intended to limit the scope of the invention tothe particular form set forth, but on the contrary, it is intended tocover such alternatives, modifications, and equivalents as may be withinthe spirit and scope of the invention as defined by the appended claims.

What is claimed is:
 1. A cookware article comprising: (a) a basematerial layer having at least a first base surface along a first side;(b) at least a first mesh layer disposed on the first base surface, thefirst mesh layer comprising a plurality of first network segmentsembedded in the first base surface and extending outward therefrom to aplanar outer first mesh surface and defining a plurality of firstinterior regions between adjacent first network segments; and (c) anonstick coating layer disposed on the first base surface, within thefirst interior regions between the adjacent first network segments, andextending outward therefrom to an outer nonstick coating surfaceadjacent to the outer first mesh surface, wherein the outer first meshsurface is disposed outward of the first base surface farther than theadjacent outer nonstick coating surface such that the nonstick coatingsurface is disposed below the outer first mesh surface.
 2. The cookwarearticle of claim 1, wherein each of the first and second portions of thefirst base surface are planar.
 3. The cookware article of claim 1,wherein the outer nonstick coating surface comprises a plurality ofdiscrete surfaces interspersed between the first network segments. 4.The cookware article of claim 3, wherein the first network segments areinterconnected and laterally surround the plurality of first interiorregions.
 5. The cookware article of claim 1, wherein the base materiallayer comprises aluminum and the first mesh layer comprises stainlesssteel first network segments.
 6. The cookware article of claim 1,wherein the cookware article is one of a pot, pan, tray, platter,platen, grill, griddle surface, baking tray, roasting pan, or pizza pan.7. The cookware article of claim 1, wherein the adjacent first networksegments define one of parallelogram, hexagonal, or rhomboidal firstinterior regions.
 8. The cookware article of claim 1, wherein theadjacent first network segments define hexagonal interior regions. 9.The cookware article of claim 1, wherein the interior regions have asurface dimension between about 0.8 mm and about 2 mm.
 10. The cookwarearticle of claim 1, wherein the network segments have a width of betweenabout 0.3 mm and about 0.5 mm.
 11. The cookware article of claim 1,wherein the network segments have a thickness between about 0.5 mm toabout 1 mm normal to the cookware article surface.
 12. The cookwarearticle of claim 11, wherein the base material layer is between 3 mm and4 mm thick.
 13. The cookware article of claim 1, wherein the interiorregions have a surface dimension between about 0.8 mm and about 2 mm andthe network segments have a width of between about 0.3 mm and about 0.5mm.
 14. The cookware article of claim 13, wherein the network segmentshave a thickness between about 0.5 mm to about 1 mm normal to thecookware article surface.
 15. The cookware article of claim 1, whereinthe base material layer comprises a second base surface along a secondside, opposite the first side, and wherein the cookware article furthercomprises: (d) a second mesh layer disposed on the second base surface,the second mesh layer comprising a plurality of second network segmentsembedded in the second surface and extending outward therefrom to aplanar outer second mesh surface and defining a plurality of secondinterior regions between adjacent second network segments.
 16. Thecookware article of claim 15, wherein the second base surface within thesecond interior regions defined by the adjacent second network segmentscomprise an outer second base surface disposed outward beyond adjacentsecond base surfaces in which the second network segments are embedded.17. The cookware article of claim 16, wherein the outer second meshsurface is disposed outward at least as far as adjacent outer secondbase surfaces.
 18. The cookware article of claim 17, wherein each of thefirst and second base surfaces are planar.
 19. The cookware article ofclaim 17, wherein the outer nonstick coating surface comprises aplurality of discrete surfaces interspersed between the first networksegments, and wherein the outer second base surface comprises aplurality of discrete surfaces interspersed between the second networksegments.
 20. The cookware article of claim 17, wherein the firstnetwork segments are interconnected and laterally surround the pluralityof first interior regions, and wherein the second network segments areinterconnected and laterally surround the plurality of second interiorregions.
 21. The cookware article of claim 17, wherein at least one ofthe first network segments, the second network segments, or bothcomprise stainless steel.
 22. The cookware article of claim 17, whereinthe first network segments comprise stainless steel and the secondnetwork segments comprise magnetic stainless steel alloy.
 23. Thecookware article of claim 22, wherein the base material layer comprisesaluminum.
 24. The cookware article of claim 17, wherein the adjacentfirst network segments define hexagonal first interior regions.
 25. Amethod of making a surface of a cookware article, the method comprising:(a) providing a base material comprising a metal or metal alloy; (b)coating at least one planar surface of the metal or metal alloy with anorganic nonstick material; and (c) compressing a mesh comprising aplurality of network segments comprising a metal or metal alloy onto thecoated surface to embed the network segments into the base material,wherein the network segments define a plurality of interior regionsbetween adjacent network segments, and wherein the network segmentsextend outward of the base material beyond the nonstick material. 26.The method of claim 25, wherein the method further comprises (d)compressing a mesh comprising a plurality of network segments comprisinga metal or metal alloy onto another surface of the base material locatedon an opposite side thereof, wherein the network segments define aplurality of interior regions between adjacent network segments, andwherein the network segments extend outward of the base material atleast as far as outer surfaces of the base material layer within theinterior regions defined between the network segments.